CN114682989A - Method and device for repairing casting in solid state - Google Patents
Method and device for repairing casting in solid state Download PDFInfo
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- CN114682989A CN114682989A CN202210249240.XA CN202210249240A CN114682989A CN 114682989 A CN114682989 A CN 114682989A CN 202210249240 A CN202210249240 A CN 202210249240A CN 114682989 A CN114682989 A CN 114682989A
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Abstract
The invention relates to a method for repairing a casting in a solid state, which comprises the following steps: s1: carrying out nondestructive testing on the casting, determining the position of the defect, and marking the position of the defect; s2: preprocessing the defect position at the marked position; s3: budgeting the amount of the required repair material according to the size of the opened groove; s41: placing a repair material into the hollow shaft; s42: the hollow shaft is driven to the defect location of the mark. The method for repairing the casting in the solid state comprises the steps of determining the position of a defect, marking the position of the defect, preprocessing the position of the defect, forming a groove, estimating the consumption of a required repairing material, avoiding the waste of the repairing material, repairing the casting by a solid-phase repairing method until the casting has no defect after nondestructive detection, completing the repairing work of the casting, and repairing the casting by the solid-phase repairing method, so that the residual stress and the deformation can be reduced, and the quality of casting repairing is improved.
Description
Technical Field
The invention relates to the technical field of casting repair methods, in particular to a method for repairing a casting in a solid state.
Background
The casting industry is the basic industry of machining, and the problems of unstable product quality, high rejection rate, large raw material consumption and energy consumption, environmental pollution and the like exist in the current casting industry, so that the defect detection and repair of castings are very important.
The existing casting repair method mainly adopts argon tungsten-arc welding, and although the method has the characteristics of low cost, simple operation, strong applicability and the like, the method is easy to generate the problems of larger heat affected zone, air holes, cracks, burning loss of alloy elements, higher residual stress, deformation and the like.
Disclosure of Invention
Therefore, the technical problem to be solved by the invention is to overcome the problems that the casting repair method in the prior art is easy to generate a large heat affected zone, air holes, cracks and the like, thereby providing a method for repairing the casting in a solid state.
In order to solve the technical problem, the invention provides a method for repairing a casting in a solid state, which comprises the following steps:
s1: carrying out nondestructive testing on the casting, determining the position of the defect, and marking the position of the defect;
s2: preprocessing the defect position of the mark, and processing the area to be repaired into a groove;
s3: budgeting the amount of the required repair material according to the size of the opened groove;
s41: placing a repair material into the hollow shaft;
s42: driving the hollow shaft to the defect position of the mark;
s43: extruding the repairing material in the hollow shaft, and filling the repairing material into the groove at the defect position;
s5: and (4) carrying out nondestructive testing on the casting, judging whether the casting still has defects, if so, returning to the step S2 until the casting does not have defects, and if not, finishing the repair.
As a further improvement of the present invention, in step S43: when the repairing material in the hollow shaft is extruded out, the repairing material is also stirred and rubbed with the layer to be repaired.
As a further improvement of the present invention, in step S2: when the area to be repaired is processed into a groove which is upward along the opening direction, the area to be repaired is processed into the groove by an inclined plane, and the included angle between the inclined plane of the groove and the plumb line is 30-60 degrees.
As a further improvement of the invention, in the steps S41-S43: when the casting is repaired, the casting is repaired by adopting the material with the same material as the casting.
As a further improvement of the present invention, in step S1: before the nondestructive testing is carried out on the casting, the casting is fixed.
As a further improvement of the present invention, in step S1: when the casting is subjected to nondestructive testing, the testing is carried out along the first direction, the defect positions are determined in sequence, and the marking is carried out at the defect positions in sequence.
As a further improvement of the invention, in the steps S41-S43: when the casting is repaired, the defect positions are repaired in sequence along the first direction.
In order to solve the above technical problem, the present invention further provides a device for solid-state repairing of a casting, comprising:
the detection module is used for carrying out nondestructive detection on the casting, determining a defect position and marking the defect position;
the device comprises a preprocessing module, a detection module and a control module, wherein the preprocessing module is used for preprocessing the defect position at the mark position so as to process the area to be repaired into a groove which is upward along the opening direction;
a budgeting module for budgeting an amount of repair material required by a size of the groove;
a charging module comprising a hollow shaft for storing a repair material;
a drive system for driving the hollow shaft to a defect location;
and the ejector rod mechanism is used for extruding the repair material in the hollow shaft so as to fill the repair material into the groove at the defect position.
As a further improvement of the invention, the repairing device further comprises a rotating sleeve, wherein the rotating sleeve is sleeved on the hollow shaft, and when the ejector rod mechanism extrudes the repairing material in the hollow shaft, the driving system drives the hollow shaft to rotate and drives the rotating sleeve to rotate so as to extrude and fill up the repairing layer.
As a further improvement of the invention, the bottom end of the rotating sleeve is also provided with an involute.
Compared with the prior art, the technical scheme of the invention has the following advantages:
the method for repairing the casting in the solid state comprises the steps of determining the position of a defect, marking the position of the defect, preprocessing the position of the defect, forming a groove, estimating the consumption of a required repairing material, avoiding the waste of the repairing material, repairing the casting by a solid-phase repairing method until the casting has no defect after nondestructive detection, completing the repairing work of the casting, and repairing the casting by the solid-phase repairing method, so that the residual stress and the deformation can be reduced, and the quality of casting repairing is improved.
Drawings
In order that the present disclosure may be more readily and clearly understood, reference is now made to the following detailed description of the present disclosure taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a schematic flow diagram of a method of solid state repair of castings in accordance with a preferred embodiment of the present invention.
Detailed Description
The present invention is further described below in conjunction with the following figures and specific examples so that those skilled in the art may better understand the present invention and practice it, but the examples are not intended to limit the present invention.
It will be understood that when an element is referred to as being "disposed on," "secured to" another element, it can be directly on the other element or intervening elements may also be present. When an element is referred to as being "secured" to, or "fixedly coupled" to another element, it can be removably secured or non-removably secured to the other element. When an element is referred to as being "connected," "pivotally connected," to another element, it can be directly connected to the other element or intervening elements may also be present. The use of the terms "vertical," "horizontal," "left," "right," "up," "down," and the like are for illustrative purposes only and do not denote a single embodiment.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.
The terms "first," "second," "third," and the like in the description herein do not denote any particular quantity or order, but rather are used to distinguish one element from another.
In some embodiments, referring to FIG. 1, a method of solid state repair of a casting of the present invention comprises the steps of:
s1: carrying out nondestructive testing on the casting, determining the position of the defect, and marking the position of the defect;
s2: preprocessing the defect position of the mark, and processing the area to be repaired into a groove;
s3: budgeting the amount of the required repair material according to the size of the opened groove;
s41: placing a repair material into the hollow shaft;
s42: driving the hollow shaft to the defect position of the mark;
s43: the repairing material in the hollow shaft of the foundation is filled into the groove at the position of the defect;
s5: and (4) carrying out nondestructive testing on the casting, judging whether the casting still has defects, if so, returning to the step S2 until the casting does not have defects, and if not, finishing the repair.
Firstly, carrying out nondestructive testing on the casting, finding and determining a defect position, marking the defect position so as to confirm the defect position in the subsequent repair process, then preprocessing the defect position, processing a region to be repaired into a groove which is upward along the opening direction, then budgeting the consumption of a required repair material according to the size of the groove, then putting the budgeted repair material into a hollow shaft, then driving the hollow shaft to reach the marked defect position, extruding the repair material in the hollow shaft, filling the repair material into the groove at the defect position, reducing the residual stress and deformation, and finally carrying out nondestructive testing and repairing on the casting again until the casting has no defect;
it should be noted that the grooves are preferably trapezoidal grooves, which are easier to fill and level up when being filled, and meanwhile, the trapezoidal grooves are more convenient for estimating the material consumption.
In one embodiment, in step S43: when the repairing material in the hollow shaft is extruded out, the repairing material is also stirred and rubbed with the layer to be repaired. When the repairing material in the hollow shaft is extruded out, the hollow shaft rotates, the repairing material and the layer to be repaired are stirred and rubbed, and the filling and repairing work is completed.
The rotating speed of the hollow shaft is 300-3000rpm, the advancing speed is 100-1000mm/min, and the single-layer thickness of the repair layer is 0.5-1.5 mm.
In another embodiment, in the step S43: and a rotating sleeve is arranged on the outer side of the hollow shaft, and when the repairing material in the hollow shaft is extruded out, the repairing layer is extruded and filled through the rotating sleeve. The repairing layer is extruded and filled through the rotating sleeve arranged on the hollow shaft, the area contacting with the repairing layer is increased, and the extruding and filling efficiency of the repairing layer can be improved.
In some embodiments, in step S2: when the area to be repaired is processed into a groove, the area to be repaired is processed into the groove by an inclined plane, and the included angle between the inclined plane of the groove and a plumb line is 30-60 degrees;
preferably, the cross-sectional shape of the groove is an isosceles trapezoid.
Comparative example 1: the included angle is 30 degrees, the slope of the groove slope is larger at the moment, and the difference between the widest part and the narrowest part of the groove is low, so that the hollow shaft does not need to move by a large margin when filling the groove, but the whole width gradient of the groove is small at the moment, so that the end part of the hollow shaft cannot be directly inserted into the bottom of the groove, namely, a repairing layer at the bottom of the groove cannot be extruded and filled;
comparative example 2: the included angle is 60 degrees, the slope of the groove slope is small at the moment, and the difference between the widest part and the narrowest part of the groove is high, so that the hollow shaft needs to move by a large margin when filling the groove, but the gradual change of the whole width of the groove is large at the moment, and the end part of the hollow shaft can be directly inserted into the bottom of the groove, thereby being convenient for extruding and filling the repairing layer at the bottom of the groove;
comparative example 3: the included angle is 45 degrees, the slope of the groove slope is moderate at the moment, the difference value between the widest part and the narrowest part of the groove is moderate, therefore, the required movement amount is moderate when the hollow shaft is used for filling the groove, the gradual change amount of the whole width of the groove is moderate at the moment, the end part of the hollow shaft can be directly inserted into the bottom of the groove, and the repairing layer at the bottom of the groove can be conveniently extruded and filled.
In some embodiments, in the steps S41-S43: when the casting is repaired, the casting is repaired by adopting the material with the same material as the casting. The casting is repaired by adopting the material with the same material as the casting, the problem that the overall attractiveness of the repaired casting is reduced due to the different materials is solved, and meanwhile, the problem that the material performance of the defect position is different from that of the original casting due to the fact that the local performance change can be avoided by adopting the material with the same material as the casting.
In some embodiments, in step S1: before the nondestructive testing is carried out on the casting, the casting is fixed. The fixed casting can be prevented from displacing in subsequent steps such as nondestructive testing, the stability of the casting in the subsequent steps is improved, and the problem that the filling layer is uneven due to shaking of the casting during filling is avoided.
In some embodiments, in step S1: when the casting is subjected to nondestructive detection, detection is carried out along a first direction, defect positions are determined in sequence, and marking is carried out on the defect positions in sequence. Through determining the defect positions in sequence and marking the defect positions in sequence, the defect positions can be sequenced, comparison between the marked sequence number and the actually repaired marked sequence number is facilitated in the subsequent repairing process, and therefore the missed repairing mark is found out conveniently.
In some embodiments, in the steps S41-S43: when the casting is repaired, the defect positions are repaired in sequence along the first direction. And repairing the defect positions in sequence according to the first direction, namely repairing according to the sequence of the marked sequence numbers, so that the phenomenon of missing repair can be further avoided, and the repair efficiency is improved.
In some embodiments, an apparatus of the present invention for solid state repair of castings includes:
the detection module is used for carrying out nondestructive detection on the casting, determining a defect position and marking the defect position;
the device comprises a preprocessing module, a detection module and a control module, wherein the preprocessing module is used for preprocessing the defect position at the mark position so as to process the area to be repaired into a groove which is upward along the opening direction;
a budgeting module for budgeting an amount of repair material required by a size of the groove;
a charging module comprising a hollow shaft for storing a repair material;
a drive system for driving the hollow shaft to a defect location;
and the ejector rod mechanism is used for extruding the repair material in the hollow shaft so as to fill the repair material into the groove at the defect position.
The casting is subjected to nondestructive detection through the detection module, the defect position is determined, the defect position is marked, the casting is subjected to pretreatment processing through the pretreatment module, a groove is formed in the defect position on the casting, the consumption of the required repair material is estimated through the estimation module according to the size of the groove, then the repair material is placed into the hollow shaft through the feeding module, the hollow shaft is moved to the defect position through the driving system, finally, the repair material in the hollow shaft is extruded through the ejector rod mechanism, and the repair material is filled into the groove in the defect position;
the ejector rod mechanism may be a screw extrusion structure, a cylinder piston extrusion structure, or the like, which can extrude and push the repair material from the hollow shaft.
In some embodiments, the repair device further comprises a rotating sleeve, the rotating sleeve is sleeved on the hollow shaft, and when the ejector rod mechanism extrudes the repair material in the hollow shaft, the driving system drives the hollow shaft to rotate, so as to drive the rotating sleeve to rotate, so as to extrude and fill up the repair layer.
When the hollow shaft rotates, the rotary sleeve rotates along with the hollow shaft, and the repairing layer is extruded and filled, so that the repairing layer is more compact and smooth;
it should be noted that the rotating sleeve is preferably of trapezoidal cross section, with its upper base below the lower base, so that the repair material of the repair layer can be pressed downwards.
In some embodiments, the bottom end of the rotating sleeve is further provided with an involute curve. The involute is arranged at the bottom end of the rotary sleeve, so that the friction force between the rotary sleeve and the repairing layer can be increased, and meanwhile, the flowing rate of the repairing material driven by the rotary sleeve when rotating can be improved.
It should be understood that the above examples are only for clarity of illustration and are not intended to limit the embodiments. Other variations and modifications will be apparent to persons skilled in the art in light of the above description. And are neither required nor exhaustive of all embodiments. And obvious variations or modifications of the invention may be made without departing from the spirit or scope of the invention.
Claims (10)
1. A method of solid state repair of a casting, comprising the steps of:
s1: carrying out nondestructive testing on the casting, determining the position of the defect, and marking the position of the defect;
s2: preprocessing the defect position of the mark, and processing the area to be repaired into a groove;
s3: budgeting the amount of the required repair material according to the size of the opened groove;
s41: placing a repair material into the hollow shaft;
s42: driving the hollow shaft to the defect position of the mark;
s43: extruding the repairing material in the hollow shaft, and filling the repairing material into the groove at the defect position;
s5: and (4) carrying out nondestructive testing on the casting, judging whether the casting still has defects, if so, returning to the step S2 until the casting does not have defects, and if not, finishing the repair.
2. The method for solid state repair of castings according to claim 1, characterized in that in step S43: when the repairing material in the hollow shaft is extruded out, the repairing material is also stirred and rubbed with the layer to be repaired.
3. The method for solid state repair of castings according to claim 1, characterized in that in step S2: when the area to be repaired is processed into a groove, the area to be repaired is processed into the groove by an inclined plane, and the included angle between the inclined plane of the groove and the plumb line is 30-60 degrees.
4. The method for solid state repair of castings according to claim 1, characterized in that in said steps S41-S43: when the casting is repaired, the casting is repaired by adopting the material with the same material as the casting.
5. The method for solid state repair of castings according to claim 1, characterized in that in step S1: before the nondestructive testing is carried out on the casting, the casting is fixed.
6. The method for solid state repair of castings according to claim 1, characterized in that in step S1: when the casting is subjected to nondestructive testing, the testing is carried out along the first direction, the defect positions are determined in sequence, and the marking is carried out at the defect positions in sequence.
7. The method for solid state repair of castings according to claim 7, wherein in the steps S41-S43: when the casting is repaired, the defect positions are repaired in sequence along the first direction.
8. An apparatus for solid state repair of castings, comprising:
the detection module is used for carrying out nondestructive detection on the casting, determining a defect position and marking the defect position;
the device comprises a preprocessing module, a detecting module and a judging module, wherein the preprocessing module is used for preprocessing the defect position at the mark position so as to process the area to be repaired into a groove which is upward along the opening direction;
a budgeting module for budgeting an amount of repair material required by a size of the groove;
a charging module comprising a hollow shaft for storing a repair material;
a drive system for driving the hollow shaft to a defect location;
and the ejector rod mechanism is used for extruding the repair material in the hollow shaft so as to fill the repair material into the groove at the defect position.
9. The apparatus for solid-state repairing of castings according to claim 8, further comprising a rotating sleeve, wherein the rotating sleeve is sleeved on the hollow shaft, when the ejector rod mechanism extrudes the repairing material in the hollow shaft, the driving system drives the hollow shaft to rotate, and drives the rotating sleeve to rotate to extrude and fill up the repairing layer.
10. An apparatus for solid state repair of castings according to claim 9, characterized in that the bottom end of the rotating sleeve is further provided with involute curves.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210249240.XA CN114682989A (en) | 2022-03-14 | 2022-03-14 | Method and device for repairing casting in solid state |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202210249240.XA CN114682989A (en) | 2022-03-14 | 2022-03-14 | Method and device for repairing casting in solid state |
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| CN114682989A true CN114682989A (en) | 2022-07-01 |
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| CN202210249240.XA Pending CN114682989A (en) | 2022-03-14 | 2022-03-14 | Method and device for repairing casting in solid state |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN119238033A (en) * | 2024-12-05 | 2025-01-03 | 山西高义钢铁有限公司 | A kind of profiled blank crack repairing device and repairing method thereof |
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| CN111655403A (en) * | 2017-10-31 | 2020-09-11 | 梅尔德制造公司 | Solid additive manufacturing system and composition and structure of material |
| CN113618330A (en) * | 2021-07-20 | 2021-11-09 | 南京航空航天大学 | Repair device and method for repairing titanium alloy and steel structure through aluminum alloy solid-phase material increase |
| CN113977188A (en) * | 2021-12-15 | 2022-01-28 | 北京工业大学 | A kind of solid-phase repair tool and method for surface defects of metal materials |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| US20090200275A1 (en) * | 2008-02-12 | 2009-08-13 | United Technologies Corporation | Solid state additive manufacturing system |
| JP2012236205A (en) * | 2011-05-11 | 2012-12-06 | Shinshu Univ | Method for repairing mold |
| CN106583916A (en) * | 2017-01-23 | 2017-04-26 | 沈阳航空航天大学 | Method for repairing long volume type defects in metal component by utilizing friction stir welding |
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